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1

CAMTECH/S/2001/JFC/1.0

JELLY FILLED CABLE


1.

INTRODUCTION
A Cable can be defined as a number of insulated metallic conductors bunched in a
compact form by providing mechanical protection and electrical insulation.
The cable in which core is fully filled with petroleum jelly, a water-resistant
compound, is called jelly filled cable.
Cable can be classified as Underground Cable (laid under ground), Submarine cable (
laid under water), Aerial cable (laid over head) and Indoor cable ( laid along the walls
of building). However, in Railways only Underground and Indoor (Switch Board)
Cables are used.
This handbook covers Construction. Laying, Jointing, Testing, and Maintenance of
(I) Polythene Insulated Polythene Sheathed Jelly Filled underground Cable with PolyAl moisture barrier & (II) Jelly filled underground quad cable (4 Quad or 6 quad) as
per Indian Railway Standard Specifications No. TC 41-97 & TC 30-97 respectively.

2.

BRIEF DESCRIPTIONS
Jelly filled cable is an underground cable having polythene as insulation on
conductors and the inter-spaces between the conductors is fully filled with petroleum
jelly. Petroleum jelly prevents ingress of moisture and water inside the core in the
event of any damages to the cable. The Cable is circular throughout its length and is
free from any physical defects.
Jelly filled cable is wound on strong wooden drums. The length of cable on any drum
is of 500 meter + 10% unless single longer lengths are specified by purchaser for
specific application. The diameter of the yoke of the drums is not be less than 20
times of the overall diameter of the cable. Both ends of the cable is kept inside the
drum To get access to the cable ends battens are is painted by red colour arrow.

JELLY FILLED CABLE

MARCH 2001

CAMTECH/S/2001/JFC/1.0

2.1

MARKING ON CABLE
To enable proper identification of the cable, the following information is embossed,
engraved or printed on the polythene jacket in case of armoured cable, and on the
sheath in case of for un-armoured cable. All the marking is in white or yellow colour:
a)
Name/Trade mark of the manufacturer
b)
IRS Specification number
c)
Year of manufacture
d)
Length (Sequential marking)
e)
Cable drum No.
f)
No. of pairs/conductor size ( Example : 100 pairs/0.63mm)
This marking is exists throughout the length at intervals of one metre.

2.2

MARKING ON CABLE DRUM


The following information is stencilled on the cable drum:
a)
b)
c)
d)
e)
f)
g)
h)
i)

2.3

Manufacturers name, brand name of trade mark


IRS Specification No.
Type of cable
Nos. of pairs and diameter of conductor
Length of cable on the drum
Direction of rotation of drum (by means of an arrow)
Approximate gross weight
Country and year of manufacture
Drum No.

ADVANTAGES OF U/G CABLE


1.

Overhead lines may come in contact with trees, bushes, etc. and cause low
insulation.

2.

Due to natural calamities and ravages of humans beings, overhead lines are
prone to a higher fault incidence.

3.

Due to headway considerations the maximum number of pairs on a pole route


is limited to 16.

NOTE:

By using underground cable all these disadvantages can be minimised. Jelly


filled cable has additional advantage over non-jelly filled cable. It prevents
ingress of water & moisture inside the cable.

JELLY FILLED CABLE

MARCH 2001

CAMTECH/S/2001/JFC/1.0

2.4

USES
In Railways Polythene Sheathed Jelly Filled Cable with Ploy-Al moisture barrier is
used for providing telephone connections to the subscribers.
Jelly filled quad cable is used for special purposes like control circuits, Axle counters
etc. in RE and Non-RE areas.
The different sizes of cables to be used for various telecommunication circuits are as
following table:
Sr. No.
1

Size of conductor
0.5mm (6.5 lb/ mile)

Circuit
Subscribers connections not exceeding 5
km.
0.63mm (10 lb/ mile)
Subscribers connections and different
lines 5 to 10 km long.
0.9mm (20 lb/ mile)
Tie lines in the same local area
Quaded cable, .9mm copper Telecommunications control circuits &
conductor (20lbs/mile)
Axle counter circuits.

2
3
4
3.

CONSTRUCTION

3.1

CONSTRUCTION PIJF TELEPHONE CABLE


Construction of a typical 20 pair polythene insulated jelly filled cable is shown below
in figure 1 & figure 2 :

E F

FIG - 1
LEGENDS

A
B
C
D
E
F
G

:
:
:
:
:
:
:

JELLY FILLED CABLE

Polythene Outer jacket


Galvanised Steel Tape
Polythene Tape
Polythene Inner sheath
Poly-Al-Laminated Tape
Core wrapping (Polyester) tape
Polythene Insulated Copper
Conductor
MARCH 2001

CAMTECH/S/2001/JFC/1.0

G
F
E
D
C
B
A
LEGENDS
A
B
C
D
E
F
G
H
I

:
:
:
:
:
:
:
:
:

POLYTHENE INSULATED COPPER CONDUCTOR


PETROLEUM JELLY
POLYSTER TAPE
JELLY FLOODING
POLY-AL-LAMINATED TAPE
POLYTHENE INNERSHEATH
POLYTHENE TAPE (DOUBLE LAYER)
GALVANISED STEEL TAPE (DOUBLE LAYER)
POLYTHENE OUTER JACKET

FIG - 2 : TYPICAL CROSS SECTION OF PIJF CABLE

POLYTHENE INSULATED CONDUCTOR

Conductors are provide for carrying electric current from one place to another.
Conductor is consist of a solid round wire of annealed high conductivity copper,
smoothly drawn, nominally circular in section, uniform in quality & resistance and
free from defects.
INSULATION
Conductor
Insulation
Insulation is provided to insulate the conductors with each other and other parts of
the cable .

JELLY FILLED CABLE

MARCH 2001

CAMTECH/S/2001/JFC/1.0

PE compound covering is provided on conductors for electrical isolation between


them. Insulation should be free from any joints or repairs. It shall fit closely on the
conductor but not adhere to it so that it is possible to remove it easily without damage
to the conductor.
The insulation resistance between each conductor shall not be less than 5000 Mega
ohms per kilometre at room temperature.
PAIR
Two insulated conductors is twisted together with uniform lay to form a pair. Each
pair takes one telephone circuit.
Polythene Insulated Polythene Sheathed Jelly Filled Cable is of different sizes
varying from 10 to 200 pairs with nominal conductor dia 0.5 or 0.63 or 0.9mm.The
standard cable sizes is 5, 10, 20, 50, 100 and 200 pairs.
UNIT
A number of twisted pairs laid up to form a group is constitute the unit.
B

PETROLEUM JELLY
The cable core is fully filled with a water resistant compound petroleum jelly which is
fully compatible with the polythene insulation, binders and tapes used in the cable.

POLY-AL-LAMINATED TAPE
After application of petroleum jelly a closed helical or longitudinal lapping of a nonhygroscopic and non-wicking polyester tape is laid over the cable core. A polythene
coated aluminium tape is applied longitudinally on the core with a minimum overlap
of 6mm. The Poly-Al-laminate is mechanically and electrically continuous throughout
the length of the cable.

POLYTHENE INNER SHEATH


The cable core complete with filled petroleum jelly and layer of Poly-Al-Laminated
tape is surrounded by a close fitted sheath of polythene. The sheath is reasonable
circular and free from pin holes, joints and other defects.

POLYTHENE TAPE
Two close helical lapping of polythene or polypropylene tape is applied over
polythene inner sheath to provide sufficient mechanical protection. This provides
bedding to armour.

GALVANISED STEEL TAPE


The sheathed cable is then armoured with two layers of galvanised steel tape. Each
layer is applied helically in the same direction.

JELLY FILLED CABLE

MARCH 2001

CAMTECH/S/2001/JFC/1.0

Joints in the armouring tape is kept to the minimum. Wherever joints are made
adequate corrosion protection is provided on both sides. If any rusty portions are
noticed on the tape the same should be painted with suitable anticorrosive paint.

F E D

LEGENDS
A: PE INSULATED CORE FILLED
WITH JELLY
B: MYLAI TAPE
C: POLY TAPE
D: PE INNER SHEATH
E: ALUMINIUM WIRE SCREENING

F: BARIUM CHROMATE TAPE


G: PVC INTERMEDIATE SHEATH
H: BEDDING TAPE
I: ARMOURING
J: OUTER SHEATH

Fig - 4
POLYTHENE OUTER JACKET
Finally the armoured cable is tightly jacketed with polythene. This jacket is
reasonably circular, free from pin holes and other defects.
3.2

CONSTRUCTION OF QUADED PIJF CABLE


Construction of a typical jelly filled quad cable (4 quad) shown below in figure 4 &
figure 5:

JELLY FILLED CABLE

MARCH 2001

CAMTECH/S/2001/JFC/1.0

J
I

H
C
G
F

LEGENDS
A
B
C
D
E
F
G
H
I
J

INSULATED CONDUCTOR
JELLY
POLYSTER TAPE
POLY-AL MOISTURE BARRIER
INNER SHEATH
SCREENING
WOVEN TAPE
INTERMEDIATE SHEATH
ARMOURING
OUTER SHEATH

Fig - 5
A

INSULATED CONDUCTOR
The conductor is composed of plain annealed high conductivity copper wire. The
conductor is circular in cross-section, free from splits, cracks and corrosion. Each
conductor is insulated with solid polythene. The insulation is applied closely and
homogeneous on the conductor

JELLY
The cable core is fully filled with a water resistant compound jelly which is fully
compatible with the polythene insulation of the conductors.

JELLY FILLED CABLE

MARCH 2001

CAMTECH/S/2001/JFC/1.0

POLYSTER TAPE
After application of the filling compound a close helical or longitudinal lapping of a
polyester tape is applied over the cable core. The tape is impregnated or flooded with
jelly.

POLY-AL MOISTURE BARRIER


Polythene coated aluminium tape is applied longitudinally on the core with a
minimum overlap of 6mm.

INNER SHEATH
Cable is sheathed with polythene. Sheath is circular, free from pin holes, joints and
other defects.

SCREEN
The cores with inner sheath is surrounded by a reasonably close fitted screen of
aluminium in the form of wires/strips.

WOVEN TAPE
The aluminium screen is wrapped with a single layer of woven tape impregnated with
barium chromate.

INTERMEDIATE SHEATH
Further protection for the screening is provided by extruded PVC circular sheath over
screening.
The colour of this intermediate sheath is grey.

ARMOURING

The galvanised steel tape armouring is applied tightly over the intermediate sheath
with two layers.The direction of the lay of the armour is opposite to that of the outer
most layer of screening.
OUTER SHEATH
The outer sheath is applied over the armouring. The colour of this outer sheath shall
be black.

JELLY FILLED CABLE

MARCH 2001

CAMTECH/S/2001/JFC/1.0

4.

COLOUR SCHEME

4.1

COLOUR SCHEME FOR PIJF TELEPHONE CABLE


The colours are applied on insulation of each conductors in such a way that pairs can
be identified easily. The colour scheme of pairs and wires in a unit is in accordance
with the table 3 given below:
COLOUR CODE FOR CONDUCTOR INSULATION
1st WIRE
(Tip)

PAIR
No.
1
2
3
4
5
6
7
8

WHITE
WHITE
WHITE
WHITE
WHITE
RED
RED
RED

9
10
11
12
13
14
15
16
17
18
19
20

BLUE
ORANGE
GREEN
BROWN
GREY
BLUE
ORANGE
GREEN
1st WIRE
(Tip)

PAIR
No.
RED
RED
BLACK
BLACK
BLACK
BLACK
BLACK
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW

2ndWIRE
(Ring)

2ndWIRE
(Ring)
BROWN
GREY
BLUE
ORANGE
GREEN
BROWN
GREY
BLUE
ORANGE
GREEN
BROWN
GREY
TABLE - 3

The different colours of the binder tape is readily distinguishable under normal
lightning condition. The colour scheme of binder tape is in accordance with table 4
for unit identification.

JELLY FILLED CABLE

MARCH 2001

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CAMTECH/S/2001/JFC/1.0

COLOUR CODE FOR TAPE OR BINDER FOR UNIT IDENTIFICATION


UNIT NUMBER

COLOUR OF BINDER

1
2
3
4
5

BLUE
ORANGE
GREEN
BROWN
GREY
TABLE - 4

NOTE :
In 10 pair units, cables colour code specified for pairs, 1 to 10 is used.
In 20 pair units, cables colour code specified for pairs, 1 to 20 is used.
The number of pairs with respect to the colour scheme is only for the purpose of
identification of pairs, the actual numerical sequence of the pairs may not be insisted
upon.

4.2

COLOUR SCHEME FOR JELLY FILLED QUADED CABLE


The colour scheme of polythene insulated quads is as per table given below :

QUAD
NO.
1
2
3
4
5
6

COLOUR OF THE CONDUCTOR


INSULATION
A
B
C
D
WIRE
WIRE
WIRE WIRE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE

ORRANGE
BLUE
BROWN
GREEN
YELLOW
BLACK

RED
RED
RED
RED
RED
RED

GREY
GREY
GREY
GREY
GREY
GREY

Wire A and wire B forms a pair. Similarly wire C and wire D forms a pair.
4.2.1 QUADDING
Four insulated conductors is stranded to form a star quad. In a quad, two conductors
diagonally opposite forms one pair and the remaining two diagonally conductors
forming the second pair. The quad is held together firmly by means of an open
helical whipping of cotton/nylon yarn or coloured tape.

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MARCH 2001

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CAMTECH/S/2001/JFC/1.0

The lays of the conductors forming the quads is differ with adjacent quads. The lay of
the conductor is so chosen that the cross-talk between the cable pairs is minimum.
The colour scheme of the quad whipping is in accordance with the table given below:

QUAD NUMBER
1
2
3
4
5
6

COLOUR SCHEME
ORANGE
BLUE
BROWN
GREEN
YELLOW
BLACK

4.2.2 LAYING UP

The quads is assembled to form a symmetrical core with a right lay. Polythene strings
of required diameter is used as fillers, if necessary, for proper circular core formation.

Each quad is retain its position in the cable with reference to the other quads.

5.

6.

STORING AND TRANSPORTATION

Cable drums shall have easy access for lifting and rolling.

When rolling the cable drum either for unloading or transportation, the drum shall
always be rotated in the direction of the arrow which is marked on the drum.

The drum shall not be rolled over objects that could cause damage to the protective
battens of the cable.

When unloading is carried out from the vehicle the drum shall not be dropped on the
ground directly to avoid damage due to impact. Fork lifter or ramp shall be used.

During all stages of storage, it is essential that the ends of the cable are effectively
sealed by end cap or in any other approved manner to avoid water entry into the cable.

It is desirable that cable drums are stored in covered shed to protect against direct
exposure to sun.

Cable drums shall not be stacked on flat side. Suitable stoppers shall be placed for
stability of the drums.
CABLE LAYING

JELLY FILLED CABLE

MARCH 2001

CAMTECH/S/2001/JFC/1.0

6.1

12

PLANNING

While planning for cabling on a route, the number of conductors required, depending
upon the circuits required should be first determined. Recommended core sizes as per
specifications shall be used.

Adequate spare conductors to a minimum of 20% of the total conductors used shall be
provided for in each main cable up to the farthest point zone, beyond this there should
be a minimum of 10% spare conductors of the total conductors used. No spare
conductors are required if the total number of conductors used is 3 or less.

After deciding the size and the number of conductors in the different types of cables
to be used on a route, a foot survey should be done to determine the best route for the
cable.

The route shall be shown clearly on a cable route plan showing the actual alignment
of track, giving offsets from permanent way or permanent structures. The diagram
should indicate the various road and track crossings, crossing with power cables,
water and sewage mains and other points of importance. It is preferable to chart the
route on a route plan on which the existing routes of power cables, etc. are shown.
Changes, if any, should be incorporated in the chart/plan.

Cable route plan shall also be approved by Engineering and Electrical departments.

As far as possible, low lying areas, platform copings, drainages, hutments, rocky
terrains, points and crossings, etc. should be avoided.

Separate cables of suitable size shall be laid for point operation.

6.2

PAYING

For paying out cables, the cable drums shall be mounted on the cable wheels. It
should be ensured that no kink is formed while paying out the cable.

The drum on the wheel shall be brought to one end of the trench and the end of the
cable freed. Cable should be laid along the trench.

A party of labourers shall move along the trench carrying cable at suitable intervals so
that the cable is not damaged due to dragging along the ground or bent unduly.

Before the cable is laid in the trench, a visual inspection of cable shall be made to see
that there is no damage to the cable. It shall be tested for insulation and continuity of
the cores. Thereafter the cable shall be laid into the trench. Record of insulation and
loop resistance must be maintained.

In cases where the wheels are not available, the drum shall be mounted on an axle at
one end of the trench and cable paid out and carried by labourers.

JELLY FILLED CABLE

MARCH 2001

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6.3

13

In no case the drum shall be rolled off on to the road for laying the cable and the
cable dragged on the ground for laying purposes.

Whenever mechanised equipment is used, the work shall be carried out by a trained
operator under the supervision of SE/JE (Telecom.)/ incharge of the work.

Trenching and cable laying work shall be carried out under the supervision of
SE/JE(Telecom.)/in-charge of the work.

Where the cable drum is in damaged condition the cable may be placed on a
horizontal revolving platform.

In no case shall the cable be unwound by taking off from the side of the drum as this
will cause formation of twist in the cable.

Paying out of cable should be done by rotating the cable drum and not by pulling the
cable with excessive force.
LAYING CABLE ABOVE GROUND
In AC electrified areas cables shall be laid underground only. Cables for out door
circuits should not normally be laid above ground. In exceptionable cases where it
becomes unavoidable, the following precautions should be taken:

(i) The cable should be suspended in wooden cleats, from cable hangers or in any other
approved manner so that no mechanical damage occurs to the cable even under
exposed condition.
(ii) The cable supports shall be so spaced as to avoid sag.
(iii) In station yards, cable shall be laid in suitably protected ducts.
(iv) Indoor cable should normally be laid on ladders, channels or in any other approved
manner. The cable should be neatly tied/laced.

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CAMTECH/S/2001/JFC/1.0

6.4

CABLE LAYING (UNDERGROUND)


Cables may be laid underground, either in trenches, in ducts, in cement troughs, in
pipes or in any other approved manner.

6.4.1 LAYING THE CABLES IN DUCTS

RCC or any other approved type of ducts may be used for laying the cable.

The ducts shall have suitable covers.

The ducts shall be of such design as to prevent water collecting in the duct.

When cables are laid in rocky area, it is desirable to protect them with split RCC
ducts of suitable design.

Where it is necessary to take the cable between the tracks, it shall be carried in
trunking kept sufficiently below the ballast level.

Where several cables of different categories have to be laid in the same trench, they
shall be placed as far as possible in the following order starting from the main track
side, so that in the event of failures the maintenance staff may easily recognise the
damaged cables:
i) Telecommunication Cable
ii) Signalling Cable or Cables
iii) Power Cable
RAILWAY
TRACK
TELECOM
CABLE
SIGNAL
CABLE
BRICKS
POWER
CABLE

LAYING OF UNDERGROUND TELECOM CABLE


WITH OTHER CABLES

JELLY FILLED CABLE

MARCH 2001

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15

Cables belonging to the Department of Telecomm. or the Electrical Department must


not be laid in the same trench along with Signal & Telecom. cables. A distance of
approximately 10 cm. must be maintained between telecommunication and signalling
cables. The signalling cables must be separated from power cables, carrying more
than 110 volts by a row of bricks between them.
6.4.2 Laying
Cable shall be laid generally as per instructions given. However, special precautions
to be taken in the station yards etc. where a number of other utilities may be existing,
may be detailed in a joint circular issued by the Civil Engineering, Signalling and
Electrical departments of the Railway.

The cable laid parallel to the track shall normally be buried at a depth of 0.80 metres
from ground level while those laid across the track must be 1.0 metre below the rail
flanges. However, in case of rocky soil, the depth may be reduced suitably. When it
concerns the laying of tail cables which serve the track apparatus, etc, the depth
should not be less than 0.50 metres.

The width of manually made cable trenches should be commensurate with number of
cables. The minimum width shall be kept as 0.3 metre. The bottom of the cable trench
should be levelled and cleared of any sharp materials. In the soft ground, the cable
should be laid at the bottom of the trench previously levelled. In the rocky ground, the
cable should be laid on a layer of sand or sifted earth of 0.05 metre thickness
previously deposited at the bottom of the trench. In both the cases the cable should
be covered with a layer of sand or sifted earth of 0.10 metre thickness and thereafter
a protective cover of trough or a layer of bricks should be placed. Bricks should be
laid on the cable breadth-wise. The trench should be back filled by sifted earth up to
its original level.

Cable Crossing

When a cable has to cross the track, it should be ensured that:I) The cable crosses the track at right angles,
ii) The cable does not cross the track under points & crossings, and
iii) The cable is laid in RCC/GI pipes, while crossing the track.
iv) ACC/GI pipes should be used for road crossing.

Wherever practical, the cable may be taken underground across the drain bed at a
suitable depth for crossing small culverts. nallahas with low flood level. If it is not
possible then GI pipes should be used on culverts or drains for crossing the cables.
When cables have to cross a metallic bridge, they should be placed inside a metallic
trough which may be filled with bituminous compound, as an anti-theft measure, with
sealing compound. The cable should be supported across the bridge in a manner
which would involve minimum vibrations to the cable and which will facilitate
maintenance work. Adequate cable length to the extent of 2 to 3 metres shall be made

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16

available at the approaches of the bridge. From surface level to embankment of the
bridges, brick channel should be made for carrying the cables.
Cable markers wherever provided should be placed at suitable intervals ( about 30
meters) and at diversion points.
While laying the cables in accordance with the above instructions, the following
instructions should be adhered to for the safety of the track:
i) Outside the station limits, the cables should generally be laid at not less than 5.5
metres from the centre of the nearest track.
iii) Within the station limits, the trenches shall preferably be dug at a distance of not
less than 3 metres from the centre of the track.
iv) At each end of the main cable an extra loop length of 6 to 8 metres should be kept.

It is desirable that the excavation of the trenches is not done in long lengths and does
not remain uncovered for a long period. It is preferable that cables are laid and
refilling done on the same day.
Back filling of the trenches should be done properly. The earth excavated shall be put
back in the trench, rammed and consolidated.
During excavation, the earth of the trenches should not be thrown on the ballast. The
earth should be thrown by the side of the trenches away from the track.
In places where cables are to be laid within 1 metre from sleeper end, digging beyond
0.50 metre shall be done in the presence of an official from Engg.Dept., and the
laying of the cable and refilling of trench should be done with least delay.
Cable joints of approved type shall only be used.
The work shall be supervised at site personally by an official of the Signal and
Telecommunication department not below the rank of a Sectional Engineer/Junior
Engineer(Telecom.).
As far as possible, the cable should be laid far away from any electrical sub station,
SSP, RTSS etc. If not possible, then cable should be laid through RCC pipes up to 50
meters either sides.
Armour & metallic sheath of the cable should be earthed at both ends of the cable in a
route.

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MARCH 2001

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7.

17

JOINTING OF CABLE
Whenever more than one cable drum length is required for laying , cable has to be
jointed.

7.1
SR
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

TOOLS REQUIRED FOR CABLE JOINTING


Tool
Crowbar
Spade
Shovel
Tent(complete)
Meggar, 500V
Tool Box
Hack Saw
Cutting Plier
Wire Nipper

Job
For digging of pit
For digging of pit
For digging of pit
For protection of joint
for cable testing
For keeping tools
For cutting steel armour
For removing armour
For removing wire
insulation and cutting
conductors
Hack Knife
For marking
Clasp Knife
for cleaning the sheath,
cutting thread etc.
File Rasp
For removing the rough
surface
File ( Triangular) For smooth finish
Screw driver
For terminating cable
Hammer Large
For Cutting
Hammer Small
For Cutting
Chisel
For Cutting
Adjustable
For tightening of nuts
spanner
Brass rule
For measurements
Dividers
For marking etc.
Shave hock
For removing plumbing
metal from old joints
Blow lamp
For plumbing heating
etc.
Soldering iron
For soldering the
twisted joints
Measuring tape For measuring the
length of cable

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CAMTECH/S/2001/JFC/1.0

7.2

CABLE JOINTING MATERIAL


1.
2.
3.
4.

Jointing Box
Jointing Kit
PVC Sleeves
Resin Core

5.
6.
7.
8.

Kerosene Oil
Copper Wire
Emery Paper
Fire Wood

7.3

JOINTING PROCEDURE

7.31

INSTALLATION PROCEDURE OF TSF

JOINT

Different types of kits are used according to size of cable. Each kit contains following
contents :
1. Heat-shrinkable sleeve
2. Stainless steel channel
3. Retention clip
4. Aluminium canister
5. Branch-off clip
6. Sheath connector assembly
7. Adhesive aluminium foil
8. PVC tape
9. Cleaning liquid kit
10. Sealant tape
11. Transparent PE sheet
12. Splice filling compound
13. Cleaning tissue
14. Emery strip
15. Armour continuity wire
16. Adhesive polyester tape
Size of TSF joint kit can be selected according to cable size as shown in table below.

Sr.
No
1
2
3
4

Size
of
cable
In
Pair

Type
of
Kit

Max.
Splice
Dia
D ( mm )

Min.
single
cable
OD
D( mm)

Max.
splice
opening
L (mm)

5, 10
& 20
50
100
200

TSF-1

42

225

525

TSF-2
TSF-3
TSF-4

42
62
92

8
22
30

350
350
500

700
700
910

JELLY FILLED CABLE

Overal
l joint
length
S(mm)

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19

Cable Preparation

Dug a pit and erect a tent over it. Keep the cables to be jointed about 50 cm above
the ground level. Select suitable size of kit according to size of cables.
Lay Cables with an overlap of one canister length. Position thermoshrink sleeve
centrally and mark the ends M1. Make a mark M2 at a distance of 100 mm from
M1.

Remover outer sheath up to M2. For armoured cables remove armour and bedding
up to 15 mm, LESS THAN M2.

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Position aluminium canister centrally and mark the Crown ends as M3.

Remove poly-al-sheath upto M3. Retain the identification marker.

Clean the jelly off the pairs using the cleaning kit as shown above (or with
cleaning solvent) ENSURE THAT THE PAIRS DO NOT OPEN OUT DURING
CLEANING.

Make two 10 mm wide parallel cuts on poly-al-sheath.

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Crimp the main sheath connector to poly-al-sheath of either cable.

In branch joints, crimp the auxiliary sheath connector to the poly-al-sheath of the
branch cables. Interconnect the assembly using the bridge clip.

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Stretch and wrap sealant tape under and over the sheath connector clips.

Adjust the splice length by positioning the cannister.

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23

Twist corresponding pairs and cut off excess length. Remember to stagger the
pairs as shown above.

Splice the conductors using suitable wire connectors.

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24

Splice bundle.

Affix transparent PE sheet on to the sealant tape and secure the ends with PVC
tape.

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25

Fill the splice bundle with splice filling compound.

Wrap the PE sheet over the splice bundle and squeeze the filling compound
uniformly.

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26

Apply PVC tape, with half overlap, firmly from middle of the splice bundle upto
one end, continue to apply in the opposite direction up to the other end and travel
back to the middle.

Filled splice bundle.

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27

Install aluminium cannister around the splice bundle, such that the parting lines of
the cannister are on the sides.

Apply one round of PVC tape in the middle to hold the cannister. Apply one layer
of PVC tape on the cannister partition line. Apply two layers of PVC tape starting
from the crown and ending a little beyond the cannister finger ends.

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28

Centre the thermoshrink sleeve and mark the ends. The surface between the ends
of the cannister and this mark is bonding surface.

Clean the bonding surface with cleaning tissue. Don not touch the surface after
cleaning.

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29

Abrade the bonding surface using abrasive strip. Do not touch the surface after
abrading.

Wrap the adhesive aluminium foil around the cable by keeping ONLY 15 mm OF
COIL INSIDE THE BONDING SURFACE.

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Flame brush the bonding surface till it becomes slightly glossy.


DO NOT OVERHEAT.

Remove protective film from the thermoshrink sleeve.

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31

Position thermoshrink sleeve centrally and insert stainless steel channel(s) through
the rails. Ensure that the channel(s) is/are on the top.

Insert channel retention clip over the channel joint, where two channels have been
used.

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32

In case of branch offs, position the branch off clip(s) as shown in the illustration ,
ensure that the channel comes on the largest cables.

Insert branch off clips between the cables on the thermoshrink sleeve. Ensure that
the branch off clip(s) is/are perpendicular to the plane of the cables. The
thermoshrink sleeve should be evenly distributed over all the cables.

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33

Start thermoshrink from the middle to either side, in branch joints shrink the side
wit the lesser number of cables first.

Tap the channel gently at the transition points adjacent to the cannister crown.
Thermoshrinking is complete when the thermochromic paint changes colour and
the adhesive oozes from the ends.

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34

Concentrate the flame on the metal part of the branch off clip till the adhesive on
the clip(s) melts and oozes out. Post heat the channels with a moving flame for 15
seconds.

Wind three rounds of the armour continuity wire over the exposed armour and
solder it. Wrap one layer of sealant tape and apply three layers of polyester tape.

Allow the joint to cool for 15 minutes before handling. Complete joint is shown
below.

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7.4

JOINTING INSTRUCTIONS FOR QUADED JELLY FILLED CABLE

I)

Mark M1 on both the cables at a distance of X from the cable end, where X is 425
mm in case of straight through & condenser joint and 455mm in case of loading coil
& transformer joint.

II)

Cut and remove the outer sheath & armour upto M1, hence middle sheath is exposed.
Mark 10mm on the outer sheath. Cut & remove outer sheath to expose the armour.

III)

Mark M2 at the distance of Y from M1, on the middle sheath, where Y is 130mm in
case of straight through & condensor joint and 170mm in case of loading coil &
transformer joint.
Cut and remove the middle sheath upto M2, hence Al shield wires are exposed.

IV)

Mark 40 mm from M2 towards the cable end, on the aluminium shield wires. Cut and
remove aluminium shield wires up to this mark, hence inner sheath is exposed.

V)

Slide the split Al. ring over Al. Shield wires and bend back the wires over the ring.

VI)

Lay cables with an overlap equal to exposed inner sheath (265mm). This will be
splice length.

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VII)

Mark 245 mm on the inner sheath from cable end on both the cables. Cut and remove
inner sheath up to this mark. Hence conductors are exposed.

VIII) Make 10mm wide parallel cut on poly-al sheath and crimp the sheath connector on
both the cables. In case of derivation joint, use auxiliary sheath connector for
derivation cable. Connect main sheath connector with auxiliary sheath connector
using bridge clip.

IX)

Wrap one round of sealant tape below & above the sheath-connecting element.

X)
XI)

Clean jelly from conductors using cleaning liquid.


Adjust the splice length and fix the cables.

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XII)

37

Complete the splicing as per the conventional practice, without disturbing the splice
bundle.

XIII) Fix TPE sheet using PVC tape around the splice bundle in such a way that pouch is
formed.

XIV) Fill the filling compound in the pouch & cover it completely with TPE sheet. Squeeze
the pouch to ensure that filling compound is evenly distributed and dia of splice
bundle is uniform through out the splice. Keep sheath connector wire inside the
pouch.

XV)

Shrink heat shrinkable tube over the copper braid in such a way that braid is evenly
exposed at both ends. Fix the insulated copper braid with steel spring roll at both ends
of the shield wire, over the aluminium rings.

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38

XVI) Remove the insulation of armour continuity wire to the required length and wrap
these rounds of it over the armour. Solder the armour continuity wire over the
exposed armour. The excess length of armour continuity wire can be tied around the
splice bundle by means of adhesive PVC tape.

XVII) Cover complete splice bundle with PVC tape by keeping armour continuity braid and
insulated copper braid inside.

XVIII) In case of derivation joint, with or without transformer, derivation cable shall be
connected first and then cover the complete splices bundle with PVC tape. The
transformer may be tied to the as shown below. Ensure that on branch side, bigger
cable is on the top.

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39

XIX) Install the aluminium cannister centrally over the splice bundle. Apply one round of
PVC tape in the centre to hold the half-shells. Cover the parting lines with PVC tape.
Wrap two layers of PVC tape tightly with 50% overlap on the cannister fingers to
form the transition. Start from the crown end and proceed to the finger end.

XX)

Cover the exposed armour with one round of sealant tape.

XXI) Centre reinforced H/S sleeve over the cannister and mark sleeve ends over the outer
sheath. The portion between this mark and cannister end is the bonding surface.

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40

XXII) Clean the bonding surface for grease and dirt with cleaning tissue. Do not touch the
surface after cleaning.
XXIII) Abrade the bonding surface circumferentially using emery strip. Do not touch surface
after abrading.
XXIV) Wrap one round of adhesive aluminium foil around the cable by keeping only 15mm
of foil inside the bonding surface.

XXV) Flame brush the bonding surface till it become glossy. Do not overheat as it could
damage the cable sheath.

XXVI) Wrap around the H.S.sleeve and position the under clip on sleeve rails at the centre.
Slide S.S. channels over the rails in such a way that they meet at the centre of the
sleeve and are held by the under clip. The channel portion of the sleeve shall be
perpendicular to the cannister parting lines.

XXVII) In the case of derivation joints, insert the branch off clip on branch side as shown.
Start shrinking the sleeve from centre and then proceed circumferentially to the
either ends. Tap the channel gently at the transition points adjacent to the cannister
crown. The shrinking is complete when thermocromic paint changes colour and
white lines appear below the channels.

XXVIII) After shrinking do not disturb the joint for atleast 30 minutes.

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8.0

TESTING
Cable must be tested for continuity, insulation and attenuation. The tests should be
carried out before and after cable laying. For maintenance purposes these tests shall
be performed every year before and after the Monsoon.

8.1

Type of tests
Tests of underground cables may be classified in to four parts:
i)
ii)
iii)
iv)

8.11

Tests during laying of cable

8.12

Test the cable for proper end sealing.


Check up the cable throughout the length for any physical damages during
transportation and handling and for manufacturing defects.
Test for Continuity & Insulation before laying the cable.

Tests after cable laying

8.13

Tests during laying of cable


Tests after cable laying
Routine tests
Tests during localisation of faults

Test for continuity


Test for insulation
Test for absence of crosses
Test for absence of contacts
Test for attenuation
Test for Cross-Talk (NEXT & FEXT)

Routine tests

Test for insulation


Test for attenuation

8.14Tests during localisation of faults


The faults that can occur in a cable can be one or more of the following type:
Break fault
: Test for Continuity
Contact or short : Test for continuity
circuit fault
Earth fault
: Test for insulation w.r.t.
earth
Low insulation : Test for insulation
Fault
8.15Precautions while testing a cable

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8.2

42

All working circuits and power supply shall be disconnected from the cable at
both ends.
Communication between the ends of cable under test shall be established by
magneto telephones with other cable/cable under test if possible, otherwise by
VHF sets.
Competent staff, required instruments and material shall be available at both the
ends.
Testing shall be carried out when conductors and insulated parts like terminal
blocks are clean and dry.
Cable conductors shall be earthed momentarily to discharge the accumulated
charge, if any, before the commencement and after the end of insulation testing.

CONTINUITY TEST
TOOLS & EQUIPMENTS REQUIRED
1. Multimeter
2. Wire nipper
3. Screw driver set
This test is carried out to confirm that the core under test is either showing break
between both ends or continuous. Testing can be commenced as per the following
procedure:
A.
B.
C.
D.

Set the knob of multimeter to check resistance at suitable lower range at one end.
Loop a pair with its mate wire at other end.
Connect the probes of multimeter to the both limbs of the pair.
Deflection of multimeter needle shows that limb is OK, otherwise there is a break
in limb under test.
E. Repeat the procedures (B) and (C) for testing of other pairs.
The above procedure is adopted for testing of continuity of terminated cable. At the
time of cable laying following procedure may be adopted for testing of continuity,
absence of cross and absence of contacts:
At one end every wire is twisted with its mate wire to form a loop in each pair. The
twists being insulated from each other by means of paper sleeves or PVC sleeves and
make the end moisture proof. At the other end i.e. testing end layers of cable should
be bound with twine to keep the wires in their proper place so that if a fault is
detected the position of the faulty wire is known. Then all the wires should earthed
with a piece of soft bare copper wire which is also connected to the cable sheath and
to the terminal of the multimeter . Disconnect the mate wire from earth and connect
to the other terminal of the multimeter, there should be a deflection indicating
continuity. Disconnect the mate wire from earth, the deflection should disappear
which proves absence of crosses of contacts. If the wires tested are OK they should be
set aside without earthing them again. If however any of the wires show a cross or
contact they are crossed or in contact come to be tested they also will show faulty.
Each pair of wires must be tested in turn in the above manner.

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8.3

INSULATION TEST
TOOLS AND INSTRUMENTS REQUIRED
1. Insulation Tester (Megger) 500V DC
2. Wire nipper

3. Screw Driver set.

This test is carried out to measure the insulation resistance of the cable under test.
Insulation resistance measured between (1) conductor to conductor and (2) conductor
to earth. Procedure is as follows:
8.31

CODUCTOR TO CONDUCTOR
(CROSS INSULATION)
Conductor A
Line
MEGGER
500 V DC

Earth
Conductor B

I)

A 500 V Insulation Tester ( Megger ) shall be used for this test and kept at one
end of the cable under test.

II)

Conductors for which cross insulation is being measured shall be connected to


at Line and Earth terminals of megger as shown in figure.

III)

Now rotate the handle of megger or press push button of megger. The reading
of meter will show the cross insulation between the conductors. Insulation
reading shall be recorded after applying the test voltage for about a minute till
a steady reading is obtained.

IV)

Replace the conductor connected to the earth terminal of megger by other


conductor of cable and take measurement.

V)

Repeat the process IV for remaining conductors.

VI)

Now connect next conductor to Line terminal of the megger & connect the
remaining conductors one by one to earth terminal of the megger and take
measurements as per procedure III , IV & V.

VII)

Record the measurements in the prescribed format. Before commencement of


cable testing necessary disconnection from traffic shall be obtained, if,
necessary.

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8.32

CONDUCTOR TO EARTH INSULATION

Line

Conductor A

MEGGER
500 V DC Earth

I)
II)
III)
IV)

V)

By this we can measure individual insulation of conductors w.r.t. earth.


Connect conductor under test to the Line terminal of the megger.
Connect earth terminal of the megger to the earth.
Rotate the handle of megger or press push button of megger. The reading of
meter will show the insulation resistance of the conductors. Insulation reading
shall be recorded after applying the test voltage for about a minute till a steady
reading is obtained.
Replace the conductor at Line terminal of the megger by another conductor
under test and repeat as process IV.

The above measurements can be adopted for terminated cable. At the time of cable
laying following procedure can be used:
To test a cable for insulation connect all the wires together at testing end with earth
and sheath of the cable and also connect with earth terminal of meggar. Insulate all
wires with each other at the other end of the cable. Remove one wire at testing end
and connect with line terminal of the meggar. Now rotate the handle of meggar or
press the push button of meggar. The reading shall show the insulation resistance of
the conductor with respect to earth and cross insulation w.r.t. other conductors.
Similarly remove other conductors from bunch and connect on line terminal of
meggar and measure insulation resistance of remain conductors.
NOTE :
1. The value of insulation resistance shall not be less than 5000 mega ohms/km at
room temperature irrespective of the size of the conductor.
2. During insulation test, meggaring should be done only for very short duration of
approximately one minute and conductor under test should be earthed
momentarily after meggaring to discharge the accumulated charge.
3. Insulation test should be done only by 100-Volt meggar during maintenance.
8.4

ATTENUATION TEST
Practically this test is conducted only for the underground jelly filled quaded cables,
laid for special purposes in railway-electrified areas or non-electrified areas. In this
test 800 Hz tone of 0db is fed on one pair and measured at the other end on the same
pair by using TMS kit or dB meter. The reading measured at far end shall give

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attenuation that can be converted into attenuation per kilometer. The average
attenuation of the pairs shall not exceed the value listed below at 200C :

8.5

The transmission loss in speech band i.e. 300-3400 Hertz and at no frquency
should not be more than 2.5 dB/Km.

The transmission loss for PIJF telephone cable should not be more than 0.4
dB/Km.

The transmission loss for quaded jelly filled cable (Loaded) should not be more
than 0.4 dB/Km.

The transmission loss for quaded jelly filled cable (Unloaded) should not be more
than 2.5 dB/Km.

Loop Resistance
The loop resistance of conductors and the tolerance on the individual values are given
in table below:

8.6

Diameter of
Conductor
in mm

Resistance per Tolerance


km. At 200 C
Ohms/Km.

0.50 mm

172 Ohm

+ 6

0.63 mm

116 Ohm

+ 4

0.90 mm

56 Ohm

+ 2

CROSS TALK TEST


The signals of one pair of the cable produces unwanted signals in other pairs due to
electrostatic and magnetic inductive effects. These unwanted signals called Cross
Talk. The first pair is called disturbing pair and other pair called disturbed pair.
The Cross Talk is depend on line length, transposition scheme used /Polling, the
frequencies involved and the level differences on the particular pairs.
The cross talk can be either Near end cross talk (NEXT).or Far end cross talk (FEXT)
or both.

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After laying, jointing and balancing cross talk measurement is carried out for quaded
jelly filled cable only.
8.6.1

NEAR END CROSS TALK (NEXT)


The cross talk measured at the end from where the signal is being fed is called near
end cross talk or NEXT.
As shown in figure below the generator end of the disturbed circuit is the near end to
the disturbing circuit and the cross talk appearing at this end is called Near end cross
talk.
At The near end the electrostatic & magnetic inductive effects are additive so the
NEXT is predominantly felt at the near end of the disturbed circuit rather than at far
end.

GENERATOR

DISTRIBUTING CIRCUIT

LOAD

DISTRIBUTED CIRCUIT

8.6.2

LOAD

FAR END CROSS TALK (FEXT)


As shown in figure below the load end of the disturbed circuit is the far end of for the
disturbing circuit and the cross talk appearing at this end is called Far End Cross
Talk.

G
E
N
E
R
A
T
O
R
S

DISTURBING

DISTURBED

LOAD

LOAD

At far end the magnetic and electrostatic inductive effects are subtractive so for larger
distance the inducing current becomes weak. So FEXT is less effective than NEXT.
8.6.3

MEASUREMENT OF CROSS TALK


MEASUREMENT OF NEXT

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1.
2.
3.

Terminate the far ends of the cable pairs with its characteristic impedance i.e.
1120 ohms.
Fed an audio tone of 800 Hz, 0dB on one pair of the cable with the help of a
TMS kit/Oscillator.
Measure the cross talk level on other pairs at feeding end with the help of a dB
meter, as shown below.

800 Hz
0 dB

1120
ohms

DISTURBING CIRCUIT

DB
METER

1120
ohms

MEASUREMENT OF FEXT
1.
2.
3.

Terminate the far ends of the cable pair on which the tone is being fed and the
near of that cable pairs on which the cross talk level is being measured with
its characteristic impedance i.e. 1120 ohms.
Fed an audio tone of 800 Hz, 0dB on one pair of the cable with the help of a
TMS kit/Oscillator.
Measure the cross talk level on other pairs at far end with the help of a dB
meter, as shown below.

800 Hz
0 dB

1120
ohms

DISTURBING CIRCUIT

1120
Ohms

DISTURBED CIRCUIT

dB
Meter

Let us assumes that on feeding a tone of 800 Hz 0 dBm one pair and measured the
level on other pair is 70 dBm. It means the cross talk is attenuated to 70 dB between
these pairs. If this value is more it shows better performance of the circuit.
RECOMMENDED CROSS TALK LEVEL
NEXT :
FEXT :

JELLY FILLED CABLE

Better than 61 dB
Better then 65 dB

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8.6.4

PRECAUTIONS
1.
2.
3.
4.

8.7

Before measurement the pair should be terminated with characteristic


impedance.
The instruments shall be connected very near to to the cable i.e. avoid long
wiring connections.
Phantom circuits, if any shall be disconnected before measurements.
The line staff should not be allowed to disturb the line during testing.

After completion of cable testing:

Ensure that all conductors have been

Test the functions of all equipments connected through the cable for their correct
response.

Check whether any polarity of any feed taken through the cable has got earthed
inadvertently.

9.0

MAINTENANCE

9.1

ROUTINE TESTS

9.2

reconnected properly.

Underground jelly filled cables shall be tested once in every year preferably before
monsoon with a meggar for insulation only and the results of tests shall be submitted to
DSTE/ASTE.
Apart from the testing performed during laying and after laying the cables, routine tests
shall also be conducted on the cables to ensure that the cable is in good condition. This
will provide data to decide as to when a cable has served its life and to replace the same
in time, to avoid complete breakdown.
All spare pairs in a cable shall be tested periodically once in a year to ensure that they are
in good condition. This will help in using the same pairs whenever a working pair has
been faulty and the circuit carried by it has to be transferred to one of the spare pair.
MAINTENANCE
Underground cable installations when laid strictly in accordance with the recommended
practice will hardly need any maintenance throughout their anticipated span of life. As far
as the buried portion of the cable is concerned, no repairs are generally possible except in
cases where moisture or water has entered the cable and is detected before it has damaged
the insulation.
All cable termination devices, pillar boxes, cable heads and glands shall be kept clean and
dry.
These parts shall be frequently inspected and any tendency for moisture or water leak
shall be immediately attended too.
Where humidity is high, particular care shall be taken regarding the condition of the cable
heads. Pillar boxes, etc, and those may be dried by charcoal fore or anhydrous gas as and
when required, taking necessary precautions against fire hazards.

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All cables shall be tested periodically to enable timely action being taken and prevent
breakdowns.
No digging operation by other department shall be allowed close to the cable route
without prior notice to the telecommunication Inspector who will take necessary
precautions to protect the cable from damage.
As a preventive measure, cable route should be periodically inspected to detect any
digging work going on the cable route or already dugged in past. This will be very helpful
to prevent the cable for being damaged if digging work is going on or to localise the fault
in the cable if route has been dugged in past.

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MARCH 2001